CVT(TR690)-56

Automatic Transmission Assembly

CONTINUOUSLY VARIABLE TRANSMISSION

10.Automatic Transmission Assembly

A: REMOVAL

1) Remove the front wheels.

2) Disconnect the ground terminal from battery sensor. <Ref. to NT-5, BATTERY, NOTE, Note.>

3) Remove the air intake duct. <Ref. to IN(w/o STI)-22, REMOVAL, Air Intake Duct.>

4) Remove the intercooler and the intercooler stay. <Ref. to IN(w/o STI)-38, REMOVAL, Intercooler.>

5) Remove the air breather hose. <Ref. to CVT(TR690)-136, REMOVAL, Air Breather Hose.>

6) Disconnect the following connectors.

• Transmission harness connectors

• Transmission radio ground terminal

• Inhibitor harness connector

• Engine harness connectors

(A) Transmission harness connectors

(B) Transmission radio ground terminal

(D) Engine harness connectors

CVT00489

(B) (C) (A) (D)

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CVT(TR690)-57

Automatic Transmission Assembly

CONTINUOUSLY VARIABLE TRANSMISSION

7) Remove the engine hanger rear.

8) Remove the harness clip from the CVTF cooler bracket.

9) Remove the starter. <Ref. to SC(w/o STI)-2, General Description.>

AT-07730

AT-07731

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CVT(TR690)-58

Automatic Transmission Assembly

CONTINUOUSLY VARIABLE TRANSMISSION

10) Remove the pitching stopper.

11) Remove the service hole plug.

CVT00490

AT-07733

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CVT(TR690)-59

Automatic Transmission Assembly

CONTINUOUSLY VARIABLE TRANSMISSION

12) Remove the four bolts combining the torque converter and drive plate while rotating the crank pulley a lit-

tle at a time in the same direction as engine revolution.

CAUTION:

• Be careful not to drop bolts into the converter housing.

• Be careful not to damage the mounting bolts.

13) Make sure the torque converter moves freely by rotating with finger through the starter installation hole.

14) Attach the ST to the converter case.

ST 498277200 STOPPER SET

CVT00492

ME-06580

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CVT(TR690)-60

Automatic Transmission Assembly

CONTINUOUSLY VARIABLE TRANSMISSION

15) Remove the primary speed sensor harness connector.

16) Remove the transmission harness stay.

AT-07735

AT-07403

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CVT(TR690)-61

Automatic Transmission Assembly

CONTINUOUSLY VARIABLE TRANSMISSION

17) Remove the CVTF cooler pipe COMPL mounting bolt.

18) Remove the pitching stopper bracket and transmission radio ground cord.

CVT00493

CVT00494

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CVT(TR690)-62

Automatic Transmission Assembly

CONTINUOUSLY VARIABLE TRANSMISSION

19) Remove the engine ground terminal.

20) Lift up the vehicle.

21) Remove the center exhaust pipe (rear). <Ref. to EX(w/o STI)-35, REMOVAL, Center Exhaust Pipe.>

22) Remove the exhaust hanger bracket.

23) Remove the CVTF drain plug to drain CVTF. <Ref. to CVT(TR690)-38, REPLACEMENT, CVTF.>

AT-07740

CVT00495

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CVT(TR690)-63

Automatic Transmission Assembly

CONTINUOUSLY VARIABLE TRANSMISSION

24) Remove the center exhaust cover.

25) Remove the secondary pressure sensor harness connector.

AT-07743

AT-07737

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CVT(TR690)-64

Automatic Transmission Assembly

CONTINUOUSLY VARIABLE TRANSMISSION

26) Remove the snap pin and washer from shifter arm and remove the select cable.

27) Remove the plate assembly.

(A) Shifter arm

(B) Snap pin

(D) Washer

(A) Select cable

(B) Plate ASSY

AT-07871

(C)

(A)

(B)

(D)

AT-07872

(A)

(B)

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CVT(TR690)-65

Automatic Transmission Assembly

CONTINUOUSLY VARIABLE TRANSMISSION

28) Drain differential gear oil. <Ref. to CVT(TR690)-42, REPLACEMENT, Differential Gear Oil.>

29) Remove the CVTF inlet hose and outlet hose.

30) Remove the CVTF cooler (with warmer feature), and using a piece of wire, affix to a location of the body

where it will not interfere with the removal/installation of the transmission.

CVT00585

AT-07742

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CVT(TR690)-66

Automatic Transmission Assembly

CONTINUOUSLY VARIABLE TRANSMISSION

31) Set the ST.

ST 41099AC000 ENGINE SUPPORT ASSY

NOTE:

Place a washer with 4 mm (0.16 in) thickness into the gap between the engine block and ST.

32) Remove the three transmission connecting bolts.

33) Lift up the vehicle.

34) Remove the propeller shaft. <Ref. to DS-12, REMOVAL, Propeller Shaft.>

35) Remove the stabilizer link. <Ref. to FS-31, REMOVAL, Front Stabilizer.>

36) Disconnect the lower arm ball joint and housing.

37) Pull out the front drive shaft from transmission using a crowbar.

NOTE:

Place cloth between the tire lever or bar and the transmission in order to avoid damaging the transmission

side retainer.

AT-08285

AT-06282

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CVT(TR690)-67

Automatic Transmission Assembly

CONTINUOUSLY VARIABLE TRANSMISSION

38) Holding the joint of front drive shaft from transmission side, pull out the drive shaft from transmission with

care not to stretch the boot.

NOTE:

• Before pulling RH front drive shaft from transmission, turn the steering wheel to left hand full lock.

• Before pulling LH front drive shaft from transmission, turn the steering wheel to right hand full lock.

39) Remove the two transmission connecting bolts and two nuts (lower side).

40) Set the transmission jack under the transmission.

NOTE:

Make sure that the support plates of transmission jack do not touch the oil pan.

41) Remove the transmission rear crossmember.

AT-05140

AT-07744

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CVT(TR690)-68

Automatic Transmission Assembly

CONTINUOUSLY VARIABLE TRANSMISSION

42) While lowering the transmission jack gradually, fully retract the engine support, and then tilt the engine

rearward.

43) Remove the transmission assembly.

NOTE:

Remove it while moving the transmission jack up and down so that the engine and transmission remain di-

rectly aligned.

44) Remove the cushion rubber.

CVT00496

AT-07338

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CVT(TR690)-69

Automatic Transmission Assembly

CONTINUOUSLY VARIABLE TRANSMISSION

B: INSTALLATION

1) Attach the ST to converter case.

ST 498277200 STOPPER SET

2) When completely overhauling the transmission, refill approx. 10 L (2.6 US qt, 8.8 Imp qt) of CVTF through

the transmission right side plug, and install the plug.

CAUTION:

Always use specified CVTF. Using other fluid will cause malfunction. <Ref. to CVT(TR690)-4, HY-

DRAULIC CONTROL AND LUBRICATION, SPECIFICATION, General Description.>

NOTE:

Use a new gasket.

Tightening torque:

35 N·m (3.6 kgf-m, 25.8 ft-lb)

ME-06580

CVT00586

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CVT(TR690)-70

Automatic Transmission Assembly

CONTINUOUSLY VARIABLE TRANSMISSION

3) Replace the front differential side retainer oil seal. <Ref. to CVT(TR690)-89, REPLACEMENT, Differential

Side Retainer Oil Seal.>

NOTE:

• Be sure to replace the differential side retainer oil seal with a new part whenever the front drive shaft is re-

moved from the transmission.

• When a new differential side retainer oil seal has been installed, replacement is not required.

4) Install the cushion rubber.

Tightening torque:

40 N·m (4.1 kgf-m, 29.5 ft-lb)

5) Mount the transmission onto the transmission jack.

6) Strike and bend the transmission hanger of transmission rear with a rubber hammer etc. so that it gets in

contact with the transmission case.

CAUTION:

Do not apply extra overload or impact to the transmission case.

AT-07338

AT-07339

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CVT(TR690)-71

Automatic Transmission Assembly

CONTINUOUSLY VARIABLE TRANSMISSION

7) Remove the pitching stopper bracket, if mounted.

8) Install the transmission onto the engine.

NOTE:

• While raising the transmission jack gradually, turn the screw of engine support, then tilt the engine forward.

• Temporarily attach the two engine connecting bolts and two nuts (lower side).

9) Install the transmission rear crossmember.

Tightening torque:

T1: 35 N·m (3.6 kgf-m, 25.8 ft-lb)

T2: 70 N·m (7.1 kgf-m, 51.6 ft-lb)

10) Tighten the two engine connecting bolts and two nuts (lower side).

Tightening torque:

50 N·m (5.1 kgf-m, 36.9 ft-lb)

AT-07873

AT-05140

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CVT(TR690)-72

Automatic Transmission Assembly

CONTINUOUSLY VARIABLE TRANSMISSION

11) Remove the transmission jack.

12) Lower the vehicle.

13) Install the three engine mounting bolts (upper side).

Tightening torque:

50 N·m (5.1 kgf-m, 36.9 ft-lb)

14) Remove the ST (STOPPER SET) from converter case.

15) Remove the ST (ENGINE SUPPORT ASSY).

ST 41099AC000 ENGINE SUPPORT ASSY

16) Match the torque converter screw hole with drive plate hole to install the bolt.

CAUTION:

• Do not drop the mounting bolt in the converter housing.

• Do not damage the mounting bolt.

Tightening torque:

25 N·m (2.5 kgf-m, 18.4 ft-lb)

AT-06282

AT-07984

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CVT(TR690)-73

Automatic Transmission Assembly

CONTINUOUSLY VARIABLE TRANSMISSION

17) Install the remaining three bolts by rotating the crank pulley a little at a time in the same direction as en-

gine revolution.

Tightening torque:

25 N·m (2.5 kgf-m, 18.4 ft-lb)

18) Install the service hole plug.

19) Install the engine ground terminals.

Tightening torque:

19 N·m (1.9 kgf-m, 14.0 ft-lb)

AT-07733

AT-07740

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CVT(TR690)-74

Automatic Transmission Assembly

CONTINUOUSLY VARIABLE TRANSMISSION

20) Install the pitching stopper bracket and transmission radio ground cord.

Tightening torque:

41 N·m (4.2 kgf-m, 30.2 ft-lb)

21) Install the CVTF cooler (with warmer feature).

Tightening torque:

23 N·m (2.3 kgf-m, 17.0 ft-lb)

CVT00494

AT-07742

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CVT(TR690)-75

Automatic Transmission Assembly

CONTINUOUSLY VARIABLE TRANSMISSION

22) Install the CVTF cooler pipe COMPL.

Tightening torque:

16 N·m (1.6 kgf-m, 11.8 ft-lb)

23) Install the CVTF inlet hose and outlet hose.

NOTE:

• Use new CVTF hoses.

• Install the CVTF hose with the painted position facing the rear side of transmission.

CVT00493

CVT00585

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CVT(TR690)-76

Automatic Transmission Assembly

CONTINUOUSLY VARIABLE TRANSMISSION

24) Install the starter. <Ref. to SC(w/o STI)-2, General Description.>

25) Install the transmission harness stay.

Tightening torque:

16 N·m (1.6 kgf-m, 11.8 ft-lb)

26) Install the pitching stopper.

Tightening torque:

T1: 50 N·m (5.1 kgf-m, 36.9 ft-lb)

T2: 58 N·m (5.9 kgf-m, 42.8 ft-lb)

AT-07403

CVT00491

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CVT(TR690)-77

Automatic Transmission Assembly

CONTINUOUSLY VARIABLE TRANSMISSION

27) Lift up the vehicle.

28) Apply grease to the side retainer oil seal lip.

29) Set the ST to side retainer.

ST 28399SA010 OIL SEAL PROTECTOR

30) Replace the circlip of the drive shaft with a new part.

31) Insert the front drive shaft spline section into transmission and remove the ST (OIL SEAL PROTECTOR).

NOTE:

• Before inserting RH front drive shaft into transmission, turn the steering wheel to left hand full lock.

• Before inserting LH front drive shaft into transmission, turn the steering wheel to right hand full lock.

32) Insert the drive shaft into the transmission securely by pressing the housing from outside of the vehicle.

33) Insert the ball joint into housing and secure with bolt.

Tightening torque:

50 N·m (5.1 kgf-m, 36.9 ft-lb)

CAUTION:

• Do not apply grease to the tapered portion of ball stud.

• Before tightening, make sure the lower side of housing and stepped section of ball joint are in con-

tact.

34) Install the stabilizer link.

Tightening torque:

60 N·m (6.1 kgf-m, 44.3 ft-lb)

AT-07746

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CVT(TR690)-78

Automatic Transmission Assembly

CONTINUOUSLY VARIABLE TRANSMISSION

35) Install the propeller shaft. <Ref. to DS-14, INSTALLATION, Propeller Shaft.>

36) Install the plate assembly to transmission.

Tightening torque:

T: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

37) Install the washer and snap pin to the shifter arm.

(A) Select cable

(B) Plate ASSY

(A) Shifter arm

(B) Snap pin

(D) Plate ASSY

(E) Washer

CS-01132

(A)

(B)

CS-01128

(C)

(A)

(B)

(E)

(D)

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CVT(TR690)-79

Automatic Transmission Assembly

CONTINUOUSLY VARIABLE TRANSMISSION

38) Connect the secondary pressure sensor harness connector.

39) Install the center exhaust cover.

Tightening torque:

18 N·m (1.8 kgf-m, 13.3 ft-lb)

AT-07737

AT-07743

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CVT(TR690)-80

Automatic Transmission Assembly

CONTINUOUSLY VARIABLE TRANSMISSION

40) Install the exhaust hanger bracket.

Tightening torque:

23 N·m (2.3 kgf-m, 17.0 ft-lb)

41) Install the center exhaust pipe (rear). <Ref. to EX(w/o STI)-41, INSTALLATION, Center Exhaust Pipe.>

42) Connect the primary pressure sensor harness connector.

CVT00495

AT-07735

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CVT(TR690)-81

Automatic Transmission Assembly

CONTINUOUSLY VARIABLE TRANSMISSION

43) Install the engine hanger rear.

Tightening torque:

21 N·m (2.1 kgf-m, 15.5 ft-lb)

44) Install the harness clip to the CVTF cooler bracket.

AT-07730

AT-07731

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CVT(TR690)-82

Automatic Transmission Assembly

CONTINUOUSLY VARIABLE TRANSMISSION

45) Connect the following harness connectors.

• Transmission harness connectors

• Transmission radio ground terminal

• Inhibitor harness connector

• Engine harness connectors

Tightening torque:

13 N·m (1.3 kgf-m, 9.6 ft-lb)

46) Install the air breather hose. <Ref. to CVT(TR690)-136, INSTALLATION, Air Breather Hose.>

47) Install the intercooler and the intercooler stay. <Ref. to IN(w/o STI)-41, INSTALLATION, Intercooler.>

48) Install the air intake duct. <Ref. to IN(w/o STI)-22, INSTALLATION, Air Intake Duct.>

49) Install the front tires.

50) Connect the ground terminal to battery sensor. <Ref. to NT-5, BATTERY, NOTE, Note.>

51) Refill differential gear oil to adjust the differential gear oil amount. <Ref. to CVT(TR690)-41, Differential

Gear Oil.>

52) Refill CVTF to adjust the CVTF amount. <Ref. to CVT(TR690)-36, CVTF.>

53) Perform the variator chain break-in.

CAUTION:

Always execute the variator chain break-in after the replacement of the following.

• Variator chain replacement

• Primary pulley and secondary pulley replacement

54) Perform the operation for clearing AT learning value. <Ref. to CVT(diag)-17, OPERATION, Clear Mem-

ory Mode.>

55) Perform the operation of AT learning mode. <Ref. to CVT(diag)-23, Learning Control.>

56) Perform the road test to make sure there is no fault. <Ref. to CVT(TR690)-45, INSPECTION, Road

Test.>

(A) Transmission harness connectors

(B) Transmission radio ground terminal

(D) Engine harness connectors

CVT00489

(B) (C) (A) (D)

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